Embodiments described herein may include devices and methods of manufacturing sensors for monitoring physiological parameters of a patient. Specifically, embodiments disclose the use of conductive and nonconductive coating materials to increase comfort of sensor and increase accuracy of the parameters...http://www.google.com.au/patents/US7880884?utm_source=gb-gplus-sharePatent US7880884 - System and method for coating and shielding electronic sensor components

System and method for coating and shielding electronic sensor componentsUS 7880884 B2

Abstract

Embodiments described herein may include devices and methods of manufacturing sensors for monitoring physiological parameters of a patient. Specifically, embodiments disclose the use of conductive and nonconductive coating materials to increase comfort of sensor and increase accuracy of the parameters measured. The sensor may include a flexible circuit and an optical device with an active face. A generally opaque, nonconductive coating may be disposed over the optical device, except for the active face, which allows for passage of light to the active face. The nonconductive coating may comprise a medical grade silicone of a specified thickness. A second conductive layer may be disposed on a portion of the conductive layer, to provide a Faraday shield for the optical device.

Images(7)

Claims(21)

1. A sensor assembly, comprising:

a flexible circuit comprising an optical device having an active face; and

a coating coated on a portion of the flexible circuit and capable of inhibiting light from reaching the optical device other than at the active face, wherein the coating comprises a generally opaque, nonconductive material capable of inhibiting the passage of one or more wavelengths of light.

7. The sensor assembly of claim 1, wherein the coating comprises a neoprene, and/or an isoprene.

8. The sensor assembly of claim 1, wherein the coating has a thickness between about 0.005 inch and about 0.020 inch.

9. A flexible circuit assembly, comprising:

a first optical device capable of emitting light;

a second optical device capable of receiving the light emitted from the first optical device after passing through tissue; and

a coating disposed over the first and second optical devices by dipping, spraying, or molding, wherein the coating comprises a generally opaque, nonconductive material capable of inhibiting the direct transmission of light from the first optical device to the second optical device.

16. The flexible circuit assembly of claim 9, wherein the coating has a thickness between about 0.005 inch and about 0.020 inch.

17. A sensor assembly, comprising:

a flexible circuit assembly, comprising:

a first optical device capable of emitting light;

a second optical device capable of receiving the light from the first optical device, after passing through tissue;

a first coating disposed over the first and second optical devices, wherein the first coating comprises a generally opaque, nonconductive material capable of inhibiting the direct transmission of light from the first optical device to the second optical device; and

a second coating disposed over the first coating, wherein the second coating comprises a conductive material.

18. The sensor assembly of claim 17, comprising a third coating disposed over the second coating, wherein the third coating comprises a generally nonconductive material.

19. The sensor assembly of claim 18, comprising a skin contacting layer disposed on one side of the third coating of the flexible circuit.

20. The sensor assembly of claim 19, comprising at least one window layer disposed on the skin contacting layer.

21. The sensor assembly of claim 17, wherein the first coating comprises a medical grade silicone having a thickness between about 0.005 inch and about 0.020 inch.

Description

BACKGROUND

The present disclosure relates generally to medical devices and, more particularly, to sensors used for sensing physiological parameters of a patient.

This section is intended to introduce the reader to aspects of the art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

In the field of medicine, doctors often desire to monitor certain physiological characteristics of their patients. Accordingly, a wide variety of devices and techniques have been developed for monitoring physiological characteristics. Such devices and techniques provide doctors and other healthcare personnel with the information they need to provide the best possible healthcare for their patients. As a result, these monitoring devices and techniques have become an indispensable part of modern medicine.

One such monitoring technique is commonly referred to as pulse oximetry. Pulse oximetry may be used to measure various blood flow characteristics, such as the blood-oxygen saturation of hemoglobin in arterial blood and/or the rate of blood pulsations corresponding to each heartbeat of a patient.

The devices based upon pulse oximetry techniques are commonly referred to as pulse oximeters. Pulse oximeters typically utilize a non-invasive sensor that is placed on or against a patient's tissue that is well perfused with blood, such as a patient's finger, toe, forehead or earlobe. The pulse oximeter sensor emits light and photoelectrically senses the absorption and/or scattering of the light after passage through the perfused tissue. A photo-plethysmographic waveform, which corresponds to the cyclic attenuation of optical energy through the patient's tissue, may be generated from the detected light. Additionally, one or more physiological characteristics may be calculated based upon the amount of light absorbed or scattered. More specifically, the light passed through the tissue may be selected to be of one or more wavelengths that may be absorbed or scattered by the blood in an amount correlative to the amount of the blood constituent present in the blood. The amount of light absorbed and/or scattered may then be used to estimate the amount of blood constituent in the tissue using various algorithms.

For example, a reflectance-type sensor placed on a patient's forehead may emit light into the skin and detect the light that is “reflected” back after being transmitted through the forehead tissue. A transmission-type sensor may be placed on a finger; wherein the light waves are emitted through and detected on the opposite side of a finger. In either case, the amount of light detected may provide information that corresponds to valuable physiological patient data. The data collected by the sensor may be used to calculate one or more of the above physiological characteristics based upon the absorption or scattering of the light. For instance, the emitted light is typically selected to be of one or more wavelengths that are absorbed or scattered in an amount related to the presence of oxygenated versus de-oxygenated hemoglobin in the blood. The amount of light absorbed and/or scattered may be used to estimate the amount of the oxygen in the tissue using various algorithms.

The sensors generally include an emitter that emits the light and a detector that detects the light. The emitter and detector may be located on a flexible circuit that allows the sensor to conform to the appropriate site on the patient's skin, thereby making the procedure more comfortable for a patient. During use, the emitter and detector may be held against the patient's skin to facilitate the light being directed into and received from the skin of the patient. For example, the sensor may be applied to a patient's forehead. To aid in the sensor's proper placement and the proper application of pressure by the sensor to the forehead site, some forehead sensors are maintained at the forehead site by either the assistance of an adhesive layer, a headband or a hat. Any number of methods may be used to press the sensor against the patient's skin to facilitate the light being directed into and received from the skin of the patient.

A properly fitted sensor will allow the emitted light to travel through the tissue of the site and be detected without additional light being introduced, thereby preventing measurement distortion. However, in practice, the design of the sensor may not provide a tight fit between the sensor and the surface of the patient's skin. Further, to reduce measurement error, protective layers may be applied to the sensors to prevent external light from being detected by the sensor. In certain places on the flexible circuit, protective layers may delaminate, leading to shunting, where light is transmitted directly between the emitter and detector, leading to inaccurate measurements. In addition, layers added to the sensor may be uncomfortable to the patient, especially if they are delaminating.

Moreover, to increase accuracy, a photodetector of the sensor may be encompassed by a layer of wire mesh to shield the photodetector from external electromagnetic fields. The wire mesh layer may contribute to the delamination of the light blocking layer, exacerbating the shunting and measurement issues. Further, proper application of the light-blocking layer and the wire mesh layer can be time consuming. There is a need, therefore, for an improved arrangement for blocking external light and external static fields that will improve accuracy and comfort of the sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the disclosure may become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 illustrates a patient monitoring system coupled to a multi-parameter patient monitor and a sensor assembly including an optical sensor, in accordance with an embodiment;

FIG. 2 is a drawing of a hat, with an embodiment of the presently disclosed sensor assembly mounted in the hat;

FIG. 3 is a top view of a sensor assembly having a bandage style configuration, in accordance with an embodiment;

FIG. 4 is a perspective view of the optical sensor assembly, including an emitter and a detector, in accordance an embodiment;

FIG. 5 is a perspective view of the optical sensor assembly shown in FIG. 4 with a coating applied, in accordance with an embodiment;

FIG. 6 is a sectional view of an embodiment of the optical sensor assembly, including a coating and a layer, in accordance with an embodiment;

FIG. 7 is a sectional view of the optical sensor assembly, including a layer and coatings, in accordance with a further embodiment; and

FIG. 8 is a sectional view of the optical sensor assembly, including two coatings and layers, in accordance with an additional embodiment.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

As described herein, various embodiments of sensors are provided featuring various coatings to prevent shunting and interference from external light as well as external electromagnetic forces. Further the embodiments of sensors discussed are designed to fit a range of patient application areas and are designed to provide a simplified method for manufacturing. In general, embodiments of the sensors include optical components or devices (e.g., emitters and detectors) that are coated with a polymeric material that blocks the passage of unwanted light from external sources as well as directly between the emitter and detector. In further embodiments, some or all of the optical components may be coated with an additional layer of conductive polymeric material that prevents or reduces external static forces.

Prior to discussing such sensors in detail, it should be appreciated that such sensors are typically designed for use with a patient monitoring system. For example, referring now to FIG. 1, sensor 10 may be used in conjunction with patient monitor 12. Sensor 10, as depicted in FIG. 1, may be designed to be placed on a patient's forehead, either inside a hat or a headband or with an adhesive. In the depicted embodiment, cable 14 connects sensor 10 to patient monitor 12. Sensor 10 and/or cable 14 may include or incorporate one or more integrated circuit or electrical devices, such as a memory processor chip, that may facilitate or enhance communication between sensor 10 and patent monitor 12. Similarly, cable 14 may be an adaptor cable, with or without an integrated circuit or electrical device, for facilitating communication between sensor 10 and various types of monitors, including different versions of patient monitor 12 or other physiological monitors. In other embodiments, sensor 10 and patient monitor 12 may communicate via wireless means, such as using radio frequency, infrared or optical signals. In such embodiments, a transmission device may be connected to sensor 10 to facilitate wireless transmission between sensor 10 and patient monitor 12. Cable 14 (or a corresponding wireless connection) may typically be used to transmit control or timing signals from patient monitor 12 to sensor 10 and/or to transmit acquired data from sensor 10 to patient monitor 12. In other embodiments, the cable 14 may be an optical fiber that enables optical signals to be transmitted between patient monitor 12 and sensor 10.

In one embodiment, patient monitor 12 may be a suitable pulse oximeter, such as those available from Nellcor Puritan Bennett L.L.C. In other embodiments, patient monitor 12 may be a monitor suitable for measuring tissue water fractions, or other body fluid related metrics, using spectrophotometric or other techniques. Furthermore, patient monitor 12 may be a multipurpose monitor suitable for performing pulse oximetry and measurement of tissue water fraction, or other combinations of physiological and/or biochemical monitoring processes, using data acquired via the sensor 10 and/or other sensors. Moreover, to upgrade conventional monitoring functions provided by the system, patient monitor 12 may be coupled to a multi-parameter patient monitor 16 via cable 18 connected to a sensor input port and/or a cable connected to a digital communication port.

Turning now to FIG. 2, an embodiment of sensor 10 is shown inside a hat 22. The sensor may be placed inside hat 22, such as a stocking cap, so that sensor 10 may be placed on the patient's forehead area. Sensor 10 includes optical devices, such as emitter 24 and detector 26, which may be of any suitable type. For example, emitter 24 may be one or more light emitting diodes adapted to transmit one or more wavelengths of light, such as a red to infrared range, and detector 26 may be a photodetector, such as a silicon photodiode package, selected to receive light in the range emitted from emitter 24. In the embodiment, sensor 10 is coupled to cable 14 that may be used to transmit electrical and/or optical signals to and from emitter 24 and detector 26. Cable 14 may be permanently coupled to sensor 10, or it may be removably coupled to sensor 10. The removable coupling of cable 14 may be utilized in situations where sensor 10 is disposable, e.g., where a sensor is disposed of after being used on a patient.

Sensor 10, as discussed herein, may be configured for reflective type sensing. Furthermore, sensor 10 may include various structural and functional features designed to facilitate its use. An example of one such sensor and its use and construction may be found in U.S. application Ser. No. 11/199,524 titled “Medical sensor and Technique for Using the Same” and filed on Aug. 8, 2005, which is herein incorporated by reference in its entirety for all purposes. However other suitable sensor packages may also be used in conjunction with the presently disclosed techniques and devices. In the illustrated embodiment, sensor 10 includes a flexible circuit, on which emitter 24 and detector 26 may be mounted. The flexible circuit may be used to transmit signals to emitter 24 and from detector 26 via cable 14. A detailed discussion of the components of sensor 10 will be addressed below.

With regard to the location of the sensor 10 on the patient's forehead, the sensor may be situated on the lower forehead region, above the eyebrow, with the sensor optical devices located above and predominantly lateral to or centered over the iris. In the depicted embodiment, the sensor 10 may be attached to the inside band of hat 22. The precise location of the reflectance sensor in the hat allows appropriate placement of the sensor in the optimal forehead location by a user not skilled in sensor placement. It has been found that the placement of a reflectance forehead sensor is a factor in the accurate determination of a blood flow characteristic, due to the vasculature of the forehead. In addition, it has been shown that having a certain amount of pressure on the forehead sensor can reduce the incidence of venous pulsations effects on the oximeter reading. The placement of the sensor 10 in the band of the hat 22 may minimize these issues, as the placement of a hat is a fairly repeatable and predictable process. A hat-based sensor 10, as embodied by the present disclosure, may be used on patients in clinical settings, or by athletes, soldiers, firemen, or in any environment where information related to a physiological parameter, such as heart rate or oxygen saturation information is desired.

In some situations, a user may desire to place the sensor on a perfused area of the body by means of a flexible bandage. An embodiment that depicts such a bandage style sensor 28 is shown in FIG. 3. As depicted, the bandage style sensor 28 may include optical components such as emitter 24 and detector 26. In one embodiment, the bandage style sensor 28 may use an adhesive layer to attach the sensor 28 to the patient's skin. The adhesive layer may include an acrylic or synthetic rubber adhesive. Alternatively, in another embodiment, the bandage style sensor 28 may be applied without adhesive, instead being made from a foam PVC or foam polyurethane material and attached to the skin by medical tape. In one embodiment, the face or skin contacting side of the bandage sensor 28 is black so as to minimize the incidence of reflected light that does not go through the tissue. Bandage style sensor 28 may also include a flexible circuit which may be used to transmit signals to emitter 24 and from detector 26 via cable 14. The bandage style sensor 28 may be adhered to a patient's forehead, finger, toe, or suitably perfused area of the body.

FIG. 4 depicts a detailed illustration of sensor 10 prior to protection and/or shielding via a coating or other technique, as will be described below. In an embodiment, sensor 10 includes emitter 24 and detector 26 which transmit signals to a monitor via emitter line 36 and detector line 38, respectively within the cable 14. As depicted, emitter line 36 and detector line 38 may each be encompassed by a rubber material to insulate the wires from interference from external sources or each other. Further, cable 14 may include a rubber insulator that encompasses emitter line 36 and detector line 38. In the embodiment, emitter line 36 may include several wires 40 such as a positive and/or negative signal connection lead, which may be attached to emitter connection 42 via solder or other appropriate means. Similarly, detector line 38 may include wires 44 that may rout signals from detector 26 via detector connection 46. In one embodiment, detector line 38 also includes ground wire 48 which may be used to connect the monitor to a conductive Faraday shield or other conductive coating on the sensor. As previously discussed, signals may be routed between emitter 24, detector 26 and their respective lines via a flexible circuit or substrate, indicated in the embodiment by numeral 50. In an embodiment, signals may be routed from emitter connection 42 and detector connection 46 via flexible circuit 50 to emitter pins 52 and detector pins 54. Emitter pins 52 may be used to transmit signals and/or power from flex circuit 50 to emitter 24. Similarly, detector pins 54 may transmit signals and/or power to or from detector 26.

In the illustrated embodiment, flexible circuit 50 includes a plurality of electrical traces that may facilitate the transmission of power and other signals to or from the optical components. Accordingly, in an embodiment in which sensor 10 includes emitter 24, flexible circuit 50 may drive emission of one or more wavelengths emitted by emitter 24. In an embodiment in which sensor 10 includes detector 26, the flexible circuit 50 may transmit signals indicative of the light received by detector 26. Further, flexible circuit 50 may provide structural support to emitter 24 and detector 26, while allowing sensor 10 to conform to the shape of the desired region of the patient's skin. In one embodiment, the flexible circuit 50 may allow sensor 10, whether bandage, hat-style or other configuration, to be applied to and conform to a patient's skin region. In one embodiment, a hat-style sensor 10 may conform to the shape of a patient's forehead due in part to the flexibility and/or conformability of flex circuit 50, which provides solid contact between the optical components and the skin. In one hat-based embodiment, the sensor 10 may use an emitter 24, capable of emitting two discrete wavelengths and a detector 26, placed more than 2 mm away from emitter 24. In one such embodiment, the emitter 24 and detector 26 are spaced about 10-15 mm apart.

In some embodiments, the sensor 10 may only include one optical device. For example, a sensor assembly may only include an emitter which may be connected to an oximeter monitor. A separate sensor, containing a detector may also be connected to the oximeter monitor. The monitor may be used to synchronize the separate emitter and detector devices in order to acquire accurate measurements. In this embodiment, the separate emitter assembly and detector assembly may include coatings and/or layers, as discussed herein, that are tailored to the shielding and/or protection requirements for each optical device.

FIG. 5 illustrates an embodiment of sensor 10 wherein the sensor depicted in FIG. 4 has one coating or layer applied to protect and shield one or more of the optical components. The illustration also includes sectional line 6 depicting the staggered vertical plane used to construct the sectional views depicted in FIGS. 6-8. In one embodiment, emitter 24 and detector 26 feature active faces 56 of the optical devices which are generally the surfaces of the devices that receive or emit light and are located on the skin contacting side of the device.

As illustrated, a first coating 57 may cover some or all of the flexible circuit, a portion of emitter 24 and detector 26 and the exposed portion of wires 40 and 44. In one such embodiment a mask or other means, such as tape, for covering emitter 24 or detector 26 may be used to cover the active faces 56 of the optical components while first coating 57 is applied. The first coating 57 may be applied by dipping the flex circuit 50 and the attached optical components in a suitable unset coating material, such that, when removed, a first coating 57 of the desired thickness coats some or all of the flex circuit 50, the emitter 24 and the detector 26. First coating 57 may include a polymeric material such as silicone, neoprene, isoprene or other suitable nonconductive material. In one embodiment, first coating 57 may be composed of a medical grade silicone that is approximately 0.015 inch thick. After the coating material has dried, the mask over the active faces 56 may be removed, thereby removing the coating from the active faces and allowing emitter 24 and detector 26 to receive or transmit light waves. For example, in the depicted embodiment, the sensor 10 is depicted after a first coating 57 has been applied and the masks have been removed. As discussed herein, in other embodiments in which additional layers or coatings are applied, the masks may not be removed until the last layer of coating is applied and set.

In certain embodiments, the coating material 57 may provide an opaque or light blocking layer to prevent shunting between emitter 24 and detector 26 and to prevent external light from affecting the measurements. Further, the coating 57 may provide a seal around the cables, wires and flexible circuit, thereby reducing the likelihood of substances from contacting the sensor components. In other embodiments, the coatings or layers may be applied by spraying, molding or using other appropriate means to apply the desired material around sensor 10 and its components.

Certain embodiments may include only a few layers to shield and/or protect the emitter 24 and detector 26 from external sources that may interfere with the oximeter measurement. For example, as depicted in the embodiment of FIG. 6, first coating 57 of sensor 10 may contain an opaque and non-conductive material, thereby shielding the optical devices from external light and preventing shunting between emitter 24 and detector 26. In one embodiment, the first coating may encompass the entire flex circuit 50 and a portion of the optical devices including the sides of detector 26. In the depicted embodiment, the active face 56 of detector 26 is not coated by the first coating 57. It should be noted that although the sectional illustration shows only detector 26 and its coatings, emitter 24 may feature the same or similar coatings as depicted with respect to detector 26. For example, in one embodiment, first coating 57 may be disposed over the entire flex circuit 50 of sensor 10. However, in another embodiment, first coating 57 is only disposed over the portion of sensor 10 requiring protection, e.g., wire leads 40, emitter 24 and detector 26.

In one embodiment, a Faraday shield 58 may be applied over all or part of the first coating 57. The Faraday shield 58 may be composed of a conductive material to shield the optical devices from external static fields. For example, in one embodiment the Faraday shield may be composed of a copper mesh or other suitable conductive material in order to prevent degradation of the measurement signal by external static fields. In one such embodiment, Faraday shield 58 covers the optical devices and wire leads 40. Thus, the Faraday shield 58 may be used to shield wire leads and the optical devices from external static electric fields, thereby protecting the signal until it is routed to the insulated cable assemblies. In one such embodiment, the Faraday shield may be disposed on the entire length of the flex circuit 50, protecting the entire sensor 10 from external electromagnetic fields though in other embodiments, the Faraday shield 58 may be disposed on less than the entire length of the flex circuit 50. As depicted, ground wire 48 may be connected to Faraday shield 58 in certain embodiments, thereby providing a connection to ground for Faraday shield 58 via cable to a monitor.

In one embodiment, window 60 may be placed on the outer-most coating of sensor 10, thereby permitting the optical devices to emit and/or detect light without obstruction by the protected layers and/or coatings. Window 60 may be composed of any suitable transparent material, such as polyurethane that may protect the optical components while allowing light transmission to the components. The use of the term “transparent” herein to describe the window 60 generally denotes that the window 60 may freely pass the wavelengths of light emitted by the emitter 24 or detected by detector 26 with little or no degradation or attenuation. The window 60, however, may or may not allow other wavelengths to be transmitted or may reduce or attenuate such other wavelengths. In one embodiment, window 60 is placed on an opening in Faraday shield 58, which exposes active face 56 to a patient's skin.

During use of the sensor 10, windows 60 may contact a patient's skin to facilitate the transmission of light between the emitter 24, detector 26 and the patient's skin and tissue. For example, in one embodiment, the detector 26 may be disposed internal to the coatings and window 60 such that it has a clear line of sight to and through the window 60. In one embodiment, emitter 24 may be subjected to the same coatings, protections and manufacturing processes and, therefore, the descriptions of detector 26 may also pertain to the fabrication of emitter 24.

The number of and configuration of coatings and/or layers of sensor 10 may be varied in number or combination depending on several factors, such as cost, durability manufacturing limitations and size/weight constraints. A particular application may require more insulation from the Faraday shield 58 and increased durability for repeated use of the sensor than is provided by the embodiment of FIG. 6. In one embodiment, additional coatings may be applied to the sensor 10 to improve sensor performance and/or sensor comfort and durability. For example, as depicted in FIG. 7, second coating 62 may be applied after first coating 57 has been applied and has cured. In one such embodiment, the second coating 62 may be applied while the optical components are masked. The second coating 62 may be applied by dipping the flexible circuit 50 and desired optical components in a suitable unset overmold material, as previously discussed. In other embodiments, the second coating 62 may be applied by spraying on the overmold material or by using injection molding techniques.

In an embodiment, second coating 62 may be approximately the same thickness as the first coating 57, about 0.015 inch thick in one embodiment. Second coating 62 may include a polymeric composition, such as rubber or silicone, which includes a conductive material, thereby providing a Faraday shield for sensor 10. For example, in one embodiment, the conductive material included in the polymeric composition may be metallic micro-diameter beads and/or a conductive polymer, such as conductive nylon or conductive polyester urethane. In one embodiment, second coating 62 may be provided around the exposed wire leads, such as wire leads 40, as well as the optical devices, such as detector 26. In another embodiment, second coating 62 may be disposed over the entire first coating 57, thereby providing a Faraday shield for the entire sensor 10. In another embodiment, the bulk of sensor 10 may be reduced by the application of second coating 62 to only a portion of the sensor 10. Second coating 62 may be configured to allow detection of light waves from active face 56 of detector 26, via window 60. As previously described, during the application of coatings and/or layers of sensor 10, active face 56 of detector 26 may be masked over to allow the optical devices to remain uncovered when the mask is removed after application of the desired coating layers.

In an embodiment, third coating 64 may be applied to the outer portion of second coating 62 and a portion of first coating 57. In one embodiment, third coating 64 is applied by masking the optical components and dipping the flexible circuit 50 and desired optical components in a suitable unset overmold material, such as a polymeric composition. In other embodiments, the third coating 64 may be applied by spraying or injection molding the overmold material. In an embodiment, third coating 64 may be substantially thicker than first coating 57, such as 0.03125 inch thick, to provide structural support to sensor 10. In one embodiment, third coating 64 contains a non-conductive material, thereby preventing any electrical exchange between the sensor 10 and the environment. In one embodiment, third coating 64 may be disposed over the entire surface of sensor 10 and a portion of monitor cable 14, thereby providing strain relief between sensor 10 and cable 14. In another embodiment, third coating 64 may only be disposed on the outer portion of second coating 62, thereby protecting an operator or patient from electrostatic charges. In one embodiment, window 60 is placed on third coating 64, enabling the optical device to transmit or receive wavelengths of light through the window.

The thickness of first coating 57, second coating 62 and third coating 64 may depend on the desired properties of the coating or layering materials, the cost of materials, manufacturing limitations, size, weight, and/or other constraints. First coating 57, second coating 62 and third coating 64 may each be formed from one or more suitable polymeric compositions, such as a silicone, neoprene, isoprene or other suitable materials. In the case of second coating 62, the material may include an additive that has the desired conductive properties. The amount of additive needed to achieve the desired conductive properties may depend on several factors, such as environment and other application-specific facts. Examples of silicones that may be utilized for the sensor coatings include Dow Corning Silastic® Silicone Rubber or Dow Corning Dispersion Material. For example, the Silastic® rubber material may be applied by dipping the sensor in the material or injecting the material into a mold around the sensor. The Dispersion Material may be applied by spraying or dipping the sensor in the material. Moreover, the chosen material, whether Silastic®, Dispersion material or some other polymeric composition may be pigmented or may contain an opaque additive, such as carbon granules, to achieve the opacity desired for the designated coating or layer. For example, a Silastic® rubber, when used as first coating 57 may include an added pigment to achieve the opacity needed to block the wavelengths of light. The chosen pigmentation might make the material opaque to all light wavelengths or may be designed to only block those wavelengths that may affect the oximeter measurement.

In some applications, it may be desirable to provide multiple overmold layers, as discussed above, in conjunction with a flexible and comfortable sensor surface to contact the patient's skin. FIG. 8 illustrates an embodiment of sensor 10 that provides such a skin contacting layer 66 to enhance the sensor's overall comfort. As depicted, sensor 10 features the first coating 57, containing a non-conductive, opaque material that may be disposed around sensor 10 and exposes the active faces 56 of emitter 24 and detector 26. Second coating 62 may include a conductive material that acts as a Faraday shield for sensor 10. In the embodiment, second layer 62 may be disposed on top of first coating 57 and also provides an opening for active faces 56 of the optical devices. As depicted, the non-conductive third coating 64 is disposed on second layer 62 and also exposes active faces 56 of the optical devices. In the embodiment, ground wire 48 may provide a ground connection to conductive second coating 62. Further, wire lead 40 may be connected to detector connection point 44 to transmit signals to emitter 24. As depicted, a skin contacting layer 66 may be located on the skin contacting side of sensor 10. In one embodiment skin contacting layer 66 may be made of a material that conforms as the sensor is pressed against a patient's skin, such as Poron®, a foam PVC or foam polyurethane material. Moreover, window 60 may be applied to skin contacting layer 66, thereby protecting and allowing light to enter or leave the active faces 56 of the optical devices.

While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms provided. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Indeed, the present disclosed methods may not only be applied to transmission type sensors for use in pulse oximetry, but also to other sensor designs. Likewise, the present disclosure is not limited to use on foreheads but may also be applied to placement on other body parts.